Flat type battery and method of manufacture thereof



May 13, 1958 R. EMERIAT 2,834,827

FLAT TYPE BATTERY AND METHOD oF MANUFACTURE THEREOF Filed Jan@ 2o, 1955 5 sheets-sheet 1 Jg' INVENTOR l Pag/mom! Emerm? BY v ORNEY May 13, 195s R, EMERlAT 2,834,827

FLAT TYPE BATTERY AND METHOD OF MANFACTURE.' THEREOF Filed Jan. 2o, 1955 s sheets-sheet 2 figs.

INVENTOR May 13, 1958 R. EMERIAT 2,834,827

FLAT TYPE BATTERY AND METHOD OF MANUFACTURE THEREOF' Filed Jan. 20, 1955 5 Sheets-Sheet 3 INVENTOR momllmerzf ATTORN S United FLAT TYPE BATTERY AND IVIETHODOF MANUFACTURE THEREF Raymond Emeriat, Paris, France, assiguorto Societe de la Pile Leclanche, Chasseneuil du Poitou, France, a French company This invention relates to `batteries and more particularly to batteries composed of tiet-type cells whichare piled to form the battery and to methods of manufacture thereof.

Batteries of the type in question and processes of manufacturing such batteriesare presently known. However, the batteries and manufacturing procedures are not believed to have been developed to the highest-stage of perfection.

Among the detrimental features of thepresently known methods of producing such batteries are the following:

In the manufacturing process there has heretofore Vbeen considerable Waste of materials from which the individual components of the battery are assembled. lIn addition, some ofthe components have been of complicated shape and as a result have required additional operational steps for their production.

In addition, batteries have included waste space and have been of excessive dimensions for their rated capacities because of the peculiar shapes of individual components of the respective cells and, irl-addition, the thickness of the material used for the casings of the individual cells. in addition, poor t of the components into the individual cell casings has caused looseness of the latter in lthe casings. Additionally, auxiliary binding means such as adhesive :tapes or the like have been required formaintaining the cells in the required closely-tting sealing relationship necessary for battery operation. lln effect, therefore, there has beena requirement for an excess of materials necessary for creating and preserving the piled battery cells in assembled relationship.

-In addition, the customary procedure in assembling the piles of flat cells has been to gather together the numberrof cells required for a given battery into a pile and thereafter impart a single pressnreto the entire pile as va unit during the binding and sealing together of the individual cells in the pile. The pressure applied to thepile asa whole during such sealing and during the application of an overall binding to secure the compressed pile in assembled relationship is found to be irregularly distributed in Ithe individual cells of the pile both during and after completion of the sealing and binding process. i ln consequence, the electrical performances of different batteries varies considerably even though all have been produced by the same process and have the same dimensional characteristics.

The variation in electrical performance which results from the irregular distribution of pressure depends upon the fact that uniformity of Contact between engaging surfaces of adjacent cells is diflicult to secure. In addition, sufficiency of Contact between two adjacent cells varies with consequent variation inthe ohmic resistance of the battery. Furthermore, the irregularity in pressure distribution makes it diicult to insure leak-proof sealing between adjacent cells in the absence of which current leakages occur.

Besides excessive variation in performance characteriff v dening said opening.

2,334,827 Patented4 May 13, 1958 in present batteries Vand their processes of manufacture' noted herein are eliminated or materially reduced.

Additional features `and objects are to provide a .battery-manufacturing process which. is substantially simpler vand cheaper when. compared with the presently known processes.

The battery of the present invention comprises. a plurality of individual dat cells piled Vup in required number to provide a battery block with the desired output rating. Each of the cells embodies a pair. of trays, each preferably of a :thermoplastic material between whichthe other components of the cell are enclosed. Each of the trays which are adapted to 'benested one .into the other is provided with fa large bottom aperture andthe depth of each -trayis'sligh'tly .in excess of'thedepth vof a cell which. is to be forinedtherefrom. The bottom of each tray is closed over orcovered internally lbya small metallic plate of zir'1c, for'example,whichis shaped toiit the internal dimensions defined by the'side walls of `the tray. This. plate which'con'stitutes 'the vanode of the individual cell is -sealed to'thebottom 'ofthe'tray to the plate through the bottom opening'orfaperturel of the tray and to the outer vface'ofthe bottorn'p'eripheral'flange of the tray defining the `bottomopening. The conductive `coating thusserves to 'adhere'theplate to the tray and to act as atigrht joint'with the'ilan'ge The other cell components are superposed upon the-zinc plate vvithin'the4 tray. The cell is then completed by superposing or nestingthe'bottom of a second tray within the first tray abovei'its' contents and'sealing the second tray to the irst'traytby welding of the upper peripheral side Wall edges'ofthe lower tray to the bottom of thesecond tray.

The weldingA of the Vtwo trays is etlected'preferablyby appropriate application of high frequencyhealting electrodes to the necessary wa-ll partso'f the two-tra-ysduring the welding'process .and by sirrn'iltaneouly 'maintaining pressure of a determined amount Vbetween thetwonestefd trays and the cell components cincluded between them.' When a pair of cell trays has beenassembled' inthe manner indica-ted, a third tray is'positioned kor nested in the second tray over the contents of the'latter. :The same pressure previously applied betweentherstfand second trays is then exerted'between the third trayaand the second tray and -thesealing-of the peripheral` edges of the second-tray to the' bottom ofv-the third trayis4 now effected. Thereafter required contents 'areinserted into the third tray and the next tray is superposed on the third tray and sealed lthereto under pressure yas hasv .been completed) for an overall unitary: envelope "or covering :for-the battery consistingof the 4weldedwalls of the trays 'of-the individual cells'of the assembly. With this arrangement it is not'necessary to applyany external binding 4of any kind to the assernbly-tomantain it in united condition. Moreover, `because kthe trays of ,each tsucceeding individual celly are unitedrtoi "theY already` united `trays. fof YalltheV preceding-cells '.under'I precisely the 'same amount of 'pressureapplied -individually to 'each/.succeeding cell,'1the contacts between vadjacent' cells are uniform throughout and any number of battery blocks assembled in the manner described all show uniform operating characteristics.

Other objects and features of the invention will become apparent from the folowing specification and the accompanying drawings, wherein:

Fig. l is in part a vertical cross section and in part an elevational view of a complete battery block of nestedlystacked cells prepared in accord with this invention;

Fig. 2 is a fragmentary sectional view on an enlarged scale of a portion of the battery of Fig. l;

Fig. 3 is a perspectiveview of the battery block of Fig. l',

Fig. 4 is a perspective view of a battery composed of several of the blocks of Fig. 3;

Fig. 5 is a vertical exploded sectional View of elements of a cell group;`

Figs. 6-8, inclusive, are diagrammatic views of successive procedural steps in the manufacture of battery trays used in the process;

Fig. 9 is a perspective view of a completed tray;

Fig. l() is a diagrammatic view of the manner of assembly of a tray with a metallic anode and a conductive coating to form a tray unit;

Fig. 11 is a sectional view of a tray unit; and

Figs. 12a and 12b are diagrammatic views of sequential vsteps in assembling piled up cells of the invention.

Referring to the drawing, the reference character 1t) denotes a battery block made up of a pile of individual at quadrangularly-shaped cell units 11 so that in the overall shape the block is a parallellopiped. The individual cell units 11 are piled up or superposed upon each other and each consists of a tray 13 made of a suitable dielectric and thermoplastic material to permit uniting and sealing of a plurality of superposed trays carrying the cell unit components to each other to form the battery block 10 consisting of a plurality of cells.

Any suitable thermoplastic synthetic resins or other thermoplastic materials may be employed in manufacturing the trays. Vinyl resins, various cellulose compounds and other materials possessing the desired dielectric and thermoplastic properties may be used. Preferably these trays are manufactured from thin rectangular plastic strips S (Fig. 6) of the order of 0.15 mm. thickness cut from a roll of plastic sheet material of the same thickness and having desired width. The individual strips S are folded about the sides of a mandrel M (as seen in Fig. 8) having rectangular section of required internal tray dimensions with areas overlapping the end of the mandrel. This forms a quadrangular prism with an opening 14. The overlapping areas or borders of the strips S are folded down over the end to provide a peripheral ange for the opening 14. Terminal ap portions at the corners resulting from the folding are bent at right angles to the ange and welded thereto at the corners as by heat. The rectangular opening 14 with the marginal ange 15 around the opening lies at the bottom of the completed tray 13 as seen in perspective in Fig. 9.

An anode plate 16, for example, of zinc, is then inserted into each tray 13 (Fig. l0). The plate 16 is of such dimensions that it practically iills the entire inner surface of the tray bottom and rests upon the marginal flange 15 over the bottom opening 14. A thin conductive coating plate 17 of similar shape and area as that of zinc plate 16 is rendered tacky or is provided with an adhesive coating and positioned for application to the bottom of the plate carrying tray 13, and for union with the surface of plate 16 appearing in opening 14, and with the bottom face of the marginal tiange 15 under pressure provided by the movable pistons P1 and P2. This pressure slightly distorts the plate 17 to permit its effective bonding to the surface of anode plate 16 appearing in opening 14 and to the bottom of the marginal ange 15,

.4 thus tightly sealing the opening in the bottom of tray 13 (see Fig. 11).

The anode plates 16` preferably and for convenience of manufacture are cut individually to required length from a zinc strip having required width. This eliminates waste. They may be cut from other anodic material, e. g. magnesium.

The thin conductive coating plate 17 is composed of conventional materials, for example, of powdered carbon or graphite suspended in a synthetic resin binder such as polyvinyl chloride or polythene arranged in strip sheet form of the desired width from which successive plates 17 of the required length are cut as needed. The face of plate 17 whichis to be united with the anode plate 16 and the under surface of the marginal auge 15 is rendered tacky by application thereto of any suitable solvent for the binder such as trichloroethylene or of an appropriate adhesive such as a conductive cement which consists of a mixture of a conductive pigment such as graphite or acetylene black dispersed in any suitable solvent such as a ketone or an ester or mixture thereof coutaining a thermoplastic cement admixed therewith. The conductive cement or adhesive instead may be any of the electrically conductive rubber compositions formed of natural rubber or synthetic elastomers.

Each unit 18 consisting each of a tray with an anode plate 16 at its bottom united to an externally located conductive coating palte 17 (Fig. 1l) is now ready to receive the other cell constituents and to be assembled into battery blocks.

Of the other cell constituents one is a thin separator 19 of porous or bibulousl paper (Fig. 5). Each separator 19 is rectangular in shape with lateral and longitudinal dimensions each slightly in excess of the corresponding internal wall dimensions of tray 13 so that it may be shaped into a shallow dish that can be inserted into the tray 13 above the anode plate 16. This shallow dish shape is provided for reasons to be described. These separators 19 are cut successively from a roll whose Width corresponds to the desired lateral dimension of the separators. The paper strip of the roll is coated on one face with a film 20 consisting of jellied electrolyte of usual kind. This iilm 20 is conveniently applied to the paper strip of a roll by unwinding the latter and applying the tilm as a coating during its unwinding. The electrolyte nlm bearing strip is then dried and rewound. Subsequently the nlm-coated individual separators 19 are severed from the strip in the roll.

The other constituent comprises a mix cake 21 containing the usual materials of a depolarizing mix, namely, carbon and manganese dioxide, ammonium chloride and water. The mix cake 21 has a shape and peripheral dimensions substantially like those of the anode plate 16. It is materially thicker than any of the other components for reasons to be described. The individual mix cakes 21 preferably as needed are cut by a hollow punch from a strip of polarizing mix obtained by rolling of the ingredients of the mix cake into a at strip of required thickness. By rolling the mix cake to desired thickness and then punching out individual cakes as required, the water content of each mix cake 21 is retained. This is in contrast to the preparation of mix cakes by moulding with pressure which causes extrusion of the water content.- Later when the soft, punched-out moist mix cakes are assembled to form cells, their water content which is considerably higher than that of a moulded mix cake, in each cell diffuses through the porous paper separator 19 there-- of to humidity the jelliiied electrolyte 2t) on such separator. No additional humidiication is needed during assembly and no water is lost during sealing of trays together.

in assembling the tray units 1B with the cell components to form battery blocks 10 the following procedure is ern-l ployed. l

assesses l Ahighrfrequency welding arrangement (Figstf 12a.and;1 12b) comprising'a tubular. barrelStl having.;substantially'v rectangular internal section tvroughlwhich the'rtrays'13; may .move is provided.,` A movable bottom or piston' 31; tssinternallyiof the barrel 3i). A movable pressure piston: 32 vserving simultaneously as a highfrequency currentv carrying .electrode is movable downwardly andiupvvardly toward andaway from-.the upper mouth .331of .said barrel;V Reciprocally .movable sidev electrodes 34 one lforY eachf barrel face are-movable perpendicularly to thebarrel-:axis just above its mouth 33 toward and away from the sides of the movable electrode32.`

A tray 13 is placedon the barrel'30 `fso .thatitsgbottom'f ange l15 rests on the upper surface of the piston 31. The level offpiston 31 is then adjusted so that `the upperperiphz-y eral rim edges of the side walls of tray -13 project above thelevel of the mouth 33.

Arectangularly shaped insulatingplate 35 dimensioned4 to fit into the tray 13 is positioned in the latter; lying .y on:r`

the-internalzsurfaces of-anges 15.V The plate351isiprefe erably of the same material as tray 13 vandhasra center.

hole'36.' Ametallic plate116 is placed over plate 355 A'tray 13 of a tray unit 18'is then nestedly deposited onthe ,tray 13 so that the upper peripheral edgesyoftheside walls of tray 13 are in full contact with thefside walls of tray 13 of tray unit 18 nearits-bottom periphery.:

The upper electrode 32 is then lowered into'the tray 13 against the anode plate 16 to bring upper tray 13:and;with it the lower tray 13 in which it nests together anditobring., the overlapping contact junction of upper, peripheralf edges of the side walls of lower tray 13"and` the" bottomti periphery of upper trayf13 to a level just above thatpof the mouth 33' of said barrel: Upward pressure ofia'determined amount is then exerted through the `movable pistoni` 31:,to maintain the overlapping junction and .simultanea ously the side electrodes 34 are moved inwardly` toward.

the electrode 32-to press the overlapping edgesfofl bottom:- tray 1.3.against the walls of upper tray 13 and toward-the. electrode V32 while the electrodes areconnected toa highi frequency electric source (not shown). This-restablishes a heating electric field which-causes fusion orV welding'of-,i

dish shaped 4separator 19 to rest on` its bottom. The dish.

shape of the separator 19 spanningthe tray in all direc-` tions-serves to prevent all possibility of direct contact between-the mix cake 21 and zinc plate16. The thickness of cake mix 21 is such that its upper surface then lies slightly below the upper peripheral wallfedges -of tray .13;

Another tray unit 18 is then superposedl on the ytray-13,

its tray component 13 nesting within the upper peripheral'v Wall edges of the preceding tray 13. Its coating Vplate 17 is made to contact the entire upper surface of the cake mix. The electrode 32 is then moved downwardly again.-

into the upper tray 13 to shift the assembled trays and components downwardly in barrel 30 until the junction between engaging'or overlapping edges of the preceding tray 13 and the bottom of the upper tray 13 lie just'above the mouth 33 of barrel 36. Upward pressure of=a pret determined value is then exerted against the assembly by the lower piston 31 to press the surface of coating17 into firm and uniform contact with the mix cake 21`directly'- below it and, also, to maintain the overlapping junction between the two trays 13. While this pressure is so maintained` the side electrodes 34 are moved towardthe electrode 32 for effecting a fused or welded joint betweenfthel lapping edges of the preceding or undermosttray 13 andf;

lattery is withdrawn from upper: tray t The uppermost trayA 13 is then loadedin the sameway-'i successively with a separator 19,`"a :cake -mix21 and a ltray unit 18 and this assembly is thenpushedinto barrel. 3.0:

by theelectrode 32.until the .junctionrof'the overlapping edges of'thesecond .tray and the bottomfof the thirdtray l lies just above the barrel mouth 33. The'samey determined upward pressure previouslyv exerted is-.nowfapplied'fy forthe. same purposes by the, bottomfpiston 31 and* the welding orfusion of thezedgesat.saidilast-named junction of the second tray 13 to th'ebottom of'thethirtdtray.:

is effected.

Individual tray units 18 and their component elements.y

are thus successively assembled vwith' .thoseupreviously assembled in the pile. Whenthe required :number of tra;rl

units have :been successively4 assembled 'and unitedfas just described to produce a blockili'having thedesired output rating the uppermost tray unit 13 isleft unfilled by the usual cell components; namely separator 19 and;

mix cake 21. Instead asmallsplastic insulating plate: 35u12 identical with that used in bottom tray '13 is depositedzion' the uppermost surface of upper anodeuor zinc plate 16..-

The side walls of the uppermost tray 13b as seen inv Fig. 3 are then' folded over 'thevborderz'ofttheiplate 35u' and weldedi to itl vandxeach. other' toi completer;l the.=.batteryblock 10.v Anyfnumb'errof'blocks19'lmay,.as .shownzina Fig. 4, be mountedi inxan overall;.casingAtlroffpapen metal orplastic material'to providezamultbblock .battery f 41v of desired voltage.' Suitable electrical. connections not shown between'rblocksfare, voftcourse, madeandxterf minals 42: and. 43 aref provided'.

In general, it can be said that. broadly speaking.` the.

process of theiinstant application*.comprises'thepiling upf' of at cellsY which fora cellY of. theorder n comprises:

placing the components' of'saidv nth cell uponthe; first@v (fz-1) piled upand: fully completed andunited cells,`

forming an insulating tight` casingtaroundlsaid' nth4 cell..

components under a calculated pressure;and also producing with the peripheral external parts of'the casings ofthe first: (1t-1) cells all previously welded to` each othera single unitary insulating casing for 'all the n piled upr cells *formingl a battery block 10.-

Outstanding features of the-battery'block 10 manufac-'f required to maintain the assembly in its iinal form. In

addition, since each succeeding pair of trays has been welded together under a fixed determined like pressure, entire uniformity of contact between required compo-'- nents inall cells existsv 4and uniform low'ohmic'cell re sistance is a characteristic of all the cells.- Furthermore, since the plastic material used in formation of the trays 13 is comparatively thin (of the order of 0.15 mm. thickness) the side walls of the trays allow for diifusion ofI hydrogeniwhich is `slowly evolved during the shelf life of the battery. If these walls were thick (the case when molded trays are used), such diffusion can only occur withdifcultyand leads tobulges and distortions.

assembled with other cells under identical pressure conf ditionsf rather than by exertion of a single pressure at onetimeto an entire pile of cells during union. The latter practice does not provide uniform pressure distributionitozthe componentsI of individual cells. Also, cellvv to cell electrolyte leakage likely to result from the pressure distribution with single pressure practice is likely to prevent 'tight sealing off of individual cells from the others.

The process of this invention as above described also includes the advantages of complete use of available volume (less than is' lled with inert materials), and low manufacturing cost.

In addition, the process described may be extended to the manufacture of other types of electrochemical generators besides the typical carbon, manganese dioxide, ammonium chloride, zinc cell being, for example, suitable particularly also, to the manufacture of deferred action cells and air depolarized cells. With other types of cells, properly perforated plastic strips may be utilized for manufacture of the trays of the cells as herein described.

It is to be understood too that the process of cell assembly herein described is applicable as well to components having circular or other shapes as well as to those which are rectangular as hereinabove described.

While specific embodiments of the invention have been described, other variations in practice within the scope of the appended claims are possible and are contemplated. There is no intention, therefore, of limitation to the details shown and described.

What is claimed is:

l. That improvement in the process of preparing a battery block comprising n piled at cells including providing n+1 trays of thermoplastic material each having a depth in excess of the depth of a completed cell and a bottom opening and each being provided interiorly at its bottom with an anode plate overlying the bottom opening, and exteriorly on its bottom with a conductive coating plate united both to the bottom and to the anode plate appearing in the opening, loading a first of said trays with an electrolyte carrying separator and a mix cake as components of the first of said cells, nesting a second of said trays in the first so that upper wall portions of the first tray lap only the lower wall portions of the second tray and so that the conductive coating plate of the second tray isin surface contact with the mix cake in the rst tray, applying a predetermined amount of compression to the cell components between the two trays and simultaneously providing internal support for the lapped portions and externally applied, lateral pressure with heat to said lapped portions against said support for uniting said lapped portions of the'two trays permanently to complete the iirst of the cells, thereafter successively and independently repeating the loading, nesting, compression and union to complete each of the succeeding cells until n piled cells have been prepared with the n-l-l trays, all of the successive compressions utilizing like pressure and each union serving independently to unite the uppermost of the piled trays to the next preceding tray of the already united trays of preceding cells so that when n cells are completed a unitary overall covering for all the cells is defined by the united wall portions of the n+1 individual trays, and the components of each individual cell are maintained in required Contact with each other and those of adjacent cells at substantially identical pressures.

2. That improvement in the process of preparing battery lblocks comprising n piled flat cells including providing n+1 trays of thermoplastic material each having a depth in excess of the depth of a completed cell and a bottom opening and each `being provided interiorly at its bottom with an anode plate overlying the bottom opening and exteriorly on its 4bottom with a conductive coating plate united both to the bottom and to the anode plate appearing in the opening, loading a. first of said trays with an electrolyte carrying separator and a mix cake as components of the first of said cells, nesting a second of said trays in the first so that the upper Wall portions of the rst tray lap only the lower wall portions of the second tray and so that the conductive coating plate of the second tray is in full surface contact with the mix cake in the first tray, applying a predetermined amount of compression to the cell components between the two trays and simultaneously providing internal support for said lapped portions and externally applied, lateral pressure with heat to said lapped portions against said support for lapped portions of the two trays by heat fusion to complete the first of the cells, thereafter successively and independently repeating the loading, nesting, compression and heat fusion to complete each of the succeeding cells untilv n piled cells have been completed with the n-l-l trays, all of the successive compressions utilizing like pressure and each heat fusion serving independently to unite the uppermost of the piled trays to the next preceding tray of the already united trays of preceding cells so that when n cells are completed a unitary overall covering for all the cells is defined by the heat fused wall portions of the rt-l-l individual trays, and the components of each individual cell are maintained in required contact with each other and those of adjacent cells at substantially identical pressures.

3. The improvement of claim 2 wherein each tray is prepared individually from a specific length of thermoplastic strip material cut from a roll of such material, each strip length being folded into tray shape after its severance from the roll.

4. The improvement of claim 2 including preparation of each tray individually by severance of a required strip length from a roll of thermoplastic strip material, each strip length being folded into tray shape on a shaping mandrel after its severance from'the roll.

5. The improvement of claim 2 including preparation of each tray individually by severance of a specific strip length from a roll of thermoplastic strip material by folding each strip length into tray shape on a shaping mandrel after its severance from the roll, thereafter inserting an anode plate into the tray and uniting a conductive coating plate with the anode plate under pressure, each anode plate being severed in needed length from anode strip material already having desired Width, and each conductive coating plate similarly being severed in needed length from conductive coating plate material already having desired width.

6. The improvement of claim 2 including preparation of each separator by coating a surface of a strip of bibulous paper material with jellfied electrolyte, drying the coating, and subsequently severing independent separators of required length from such strip.

7. The improvement of claim 2 wherein the cake mix is stamped out into required shape from a rolled body of required thickness comprising a mixture of carbon, manganese dioxide, ammonium chloride and water.

8. A process of preparing batteries consisting of a pile of flat cells each including a tray of thermoplastic material serving as a receptacle for other cell components comprising the steps of rst nesting a second tray into a preceding tray already containing its required components so -that said preceding tray laps only the lower portions of said second tray, secondly applying a predetermined pressure between the nested trays and providing temporary internal support for the lapping portions and thirdly while maintaining said support and pressure and also applying heat and lateral external pressure to the supported lapping portions and thereby permanently uniting the nested trays along their lapping portions, fourthly inserting the required components into the second tray, lifthly nesting a third tray with the second tray so that said second tray laps only the lower portions of the third tray, sixthly applying the same predetermined pressure -between the third nested tray and the previously united preceding trays and seventhly while maintaining the lastnamed pressure uniting the third nested tray with the second tray along their lapping portions, and thereafter repeating the said fourth to seventh steps in sequence with each additional succeeding tray and its required components until a battery of the required number of cells has been prepared.

9. That improvement in the process of preparing a battery block comprising n piled flat cells including providing n+1 trays of thermoplastic material each having a depth somewhat in excess of the depth of a cell of auch block but less than the depth of two cells, said trays each being provided interiorly at its bottom with an anode plate and exteriorly on its bottom with a conductive coating united with the anode plate, loading a first of said trays with an electrolyte, a porous separator and a mix cake as components of the rst of said cells, nesting a second of said trays in the first so that the upper edge portions of the first tray lap only the lower wall portions of the second tray and so that the conductive coating of the second tray is in surface Contact with the mix cake in the first tray, applying a predetermined amount of compression to the cell components between the two trays and simultaneously providing internal support for said lapped portions and externallyapplied, later-al pressure with heat to said lapped portions against said support for uniting the lapped portions of the two trays by fusion of the thermoplastic material thereof to complete the rst of the cells, thereafter successively and independently repeating the loading, nesting, compression and fusion to complete each of the succeeding cells until n piled cells have been completed with the n+1 trays, all of the successive compression steps utilizing like pressure and each fusion step serving independently to unite the uppermost of the piled trays to the next preceding tray of the already united trays of preceding cells so that when n cells are completed a unitary overall covering for all the cells is de- 10 fined by the fused wall portions of the rt-l-l individual trays, and the components of each individual cell are maintained in required contact with each other and those of adjacent cells at substantially identical pressures.

l0. As an article of manufacture an uncased, selfsupporting, stacked battery block consisting of individual cells prepared and assembled in accord with the method of claim 1.

l1. As an article of manufacture an uncased, selfsupporting, stacked battery block consisting of individual cells prepared and assembled in accord with the method of claim 2.

12. As an article of manufacture a battery consisting of a pile of at cells prepared and asembled in accord with the method of claim 8.

13. As an article of manufacture an uncased, selfsupporting, stacked battery block consisting of n piled flat cells made of n+1 trays all prepared and assembled in accord with the method of claim 9.

` References Cited in the file of this patent UNITED STATES PATENTS 1,173,763 Baker Feb. 29, 1916 2,307,765 Deibel Jan. l12, l1943 2,307,766 Deibel Ian. 12, 1943 2,416,576 Franz et al Feb. 25, 1947 2,475,152 Rock July 5, 1949 2,593,893 King Apr. 22, 1952 2,645,676 Emeriat J'uly 14, 1953 2,649,492 Linton Aug. 18, 1953 2,684,397 Gottschall July 20, 1954 2,705,250 Kirkman Mar. 29, 1955 2,762,858 Wood sept, 11, 1956 UNTED STATES PATENT OEFE F" :GATE (MRE ,1. N

Patent No. 2,834,827 May 13, 1958 Raymond Emerat t is here-by certified that errer appears in the printed specification of the above numbered patent requiring correction and that the Said Letters Patent should read as corrected below.,

Column 3, liney 5, for "folowing" :read following --5 column A, line 28,- for "palte" read m. plate W; column 8,. line 7, before "lapped" insert uniting said Signed and sealed this 5th day of August 1958.

(SEAL) Attest:

KARL H AXLNE ROBERT c. wA'rsoN Attesting Officer 1 Comnssioner of Patents 

1. THAT IMPROVEMENT IN THE PROCESS OF PREPARING A BATTERY BLOCK COMPRISING N PILED FLAT CELLS INCLUDING PROVIDING N+1 TRAYS OF THERMOPLASTIC MATERIAL EACH HAVING A DEPTH IN EXCESS OF THE DEPTH OF A COMPLETED CELL AND A BOTTOM OPENILNG AND EACH BEING PROVIDED INTERIORLY AT ITS BOTTOM WITH AN ANODE PLATE OVERLYING THE BOTTOM OPENING, AND EXTERIORLY ON ITS BOTTOM WITH A CONDUCTIVE COATING PLATE UNITED BOTH TO THE BOTTOM AND TO THE ANODE PLATE APPEARING IN THE OPENING, LOADING A FIRST OF SAID TRAYS WITH AN ELECTROLYTE CARRYING SEPARATOR AND A MIX CAKE AS COMPONENTS OF THE FIRST OF SAID CELLS, NESTING A SECOND OF SAID TRAYS IN THE FIRST SO THAT UPPER WALL PORTIONS OF THE FIRST TRAY LAP ONLY THE LOWER WALL PORTIONS OF THE SECOND TRAY AND SO THAT THE CONDUCTIVE COATING PLATE OF THE SECOND TRAY IS IN SURFACE CONTACT WITH THE MIX CAKE IN THE FIRST TRAY, APPLYING A PREDETERMINED AMOUNT OF COMPRESSION TO THE CELL COMPONENTS BETWEEN THE TWO TRAYS AND SIMULTANEOUSLY PROVIDING INTERNAL SUPPORT FOR THE LAPPED PORTIONS AND EXTERNALLY APPLIED, LATERAL PRESSURE WITH HEAT TO SAID LAPPED PORTIONS AGAINST SAID SUPPORT FOR UNITING SAID LAPPED PORTIONS OF THE TWO TRAYS PERMANENTLY TO COMPLETE THE FIRST OF THE CELLS, THEREAFTER SUCCESSIVELY AND INDEPENDENTLY REPEATING THE LOADING, NESTING, COMPRESSION AND UNION TO COMPLETE EACH OF THE SUCCEEDING CELLS UNTIL N PILED CELLS HAVE BEEN PREPARED WITH THE N+1 TRAYS, ALL OF THE SUCCESSIVE COMPRESSIONS UTILIZING LIKE PRESSURE AND EACH UNION SERVING INDEPENDENTLY TO UNITE THE UPPERMOST OF THE PILED TRAYS TO THE NEXT PRECEDING TRAY OF THE ALREADY UNITED TRAYS OF PRECEDING CELLS SO THAT WHEN N CELLS ARE COMPLETED A UNITARY OVERALL COVERING FOR ALL THE CELLS IS DEFINED BY THE UNITED WALL PORTIONS OF THE N+1 INDIVIDUAL TRAYS, AND THE COMPONENTS OF EACH INDIVIDUAL CELL ARE MAINTAINED IN REQUIRED CONTACT WITH EACH OTHER AND THOSE OF ADJACENT CELLS AT SUBSTANTIALLY IDENTICAL PRESSURES. 